Prototype of PLC Automated Bottle Filling Plant with Predictive Maintenance

In Our project, we will be applying a PLC to control the overall system and ladder logic will be used to control the overall process. The main part of this project will be filling liquid in a bottle with a fixed quantity or fixed level by using time. Soft drink and other beverage industries can also

Project Title

Prototype of PLC Automated Bottle Filling Plant with Predictive Maintenance

Project Area of Specialization

Electrical/Electronic Engineering

Project Summary

In Our project, we will be applying a PLC to control the overall system and ladder logic will be used to control the overall process. The main part of this project will be filling liquid in a bottle with a fixed quantity or fixed level by using time. Soft drink and other beverage industries can also use these types of applications. We will be using several kinds of tools to complete the filling process.

Along with the filling process, we will be implementing IoT (Internet of Things) and Predictive Maintenance in the project.

The purpose of IoT will be that the whole process can be controlled using mobile phones sitting anywhere in the world. That will reduce manpower and physical efforts.

The purpose of Predictive Maintenance will be that it will notify us regarding any kind of major issue that may cause the process to stop working. It will notify us any time before the problem arises.

Project Objectives

• To implement bottle filling process using PLC.
• To Implement IoT so that the control will be independent.
• To implement Predictive Maintenance to reduce the time it will take in repairing and replacing.
• To reduce overall manpower and to reduce interruptions in the production system of an industry.
• To increase the production by utilizing a lesser amount of time.

Project Implementation Method

Ladder Logic Design:

We will be making a ladder logic that will be used in PLC programming to make it fully functioned.

IoT Implementation:

Internet of Things (IoT) will be designed to use with PLC so that it can be controlled using our mobile phone sitting anywhere along with monitoring of the system.

Conveyor Belts and Motors:

Belts and Motors will be then made compatible with PLC to operate the whole procedure properly.

Water Tank:

Water Tank is also been attached to a PLC in order to fill bottles.

Bottle Cap Fixer:

Cap Fixer assembly will be made compatible with PLC that will be closing the caps after successfully filling the bottles.

Predictive Maintenance:

An algorithm for predictive maintenance will be implemented in order to get notified prior to any problem caused in the system.

Benefits of the Project

Speed:

Automatic bottle fillers can produce a greater number of filled product in a shorter amount of time than using manual labor to hand fill or even fill in a semi-automatic fashion. This is probably the most obvious benefit of the equipment, as well as the most often cited motivation for adding automatic machinery.

Consistency/Reliability:

Automatic liquid fillers offer both consistency and reliability above and beyond what is typically achievable by doing a fill by hand. Whether by volume, fill level, weight, or otherwise, the automatic machines are accurate based on the filling principle being put to use. The removal of uncertainty and inconsistency is also a large benefit for packagers who need to hit specific production goals.

Time Efficient:

Using IoT and predictive maintenance will surely reduce the time taken by doing it manually or just by simple PLC. As it will be reducing manpower and making it more efficient by having an operating system on your mobile device.

Reduction in maintenance cost due to predictive maintenance:

The real costs normally associated with maintenance operations can be reduced by more than 50%. Comparison of maintenance costs includes actual labor and maintenance department overhead, as well as the actual cost of replacement parts, tools, and other equipment required to maintain the equipment.

Increased Production:

The availability of process systems increases after the implementation of a condition-based predictive maintenance program. The increase can be as much as 30%. The improvement is based strictly on machine availability and does not include improved process returns. However, a complete predictive program, which includes process parameter monitoring, can also improve the operating efficiency and, therefore, the productivity of manufacturing and processing plants.

Technical Details of Final Deliverable

• All the sensors will be operated at 5V for which step-down supply will be used.
• An Encoder motor will be used in order to have 360 degrees controlled rotation.
• Ball bearings will be used in conveyor belts to get smooth driving of the belt.
• Sensing the completion of the water bottle using the water level sensor.
• A Servo motor will be used for closing the bottle cap that will be having 2 complete cycles of 360 degrees.

Final Deliverable of the Project

HW/SW integrated system

Core Industry

Manufacturing

Other Industries

Food

Core Technology

Internet of Things (IoT)

Other Technologies

Artificial Intelligence(AI)

Sustainable Development Goals

Industry, Innovation and Infrastructure

Required Resources

If you need this project, please contact me on contact@adikhanofficial.com